Q4 2019
PROMOTING SAFETY IN THE CRANE INDUSTRY Multi-crane lifts Engineering and executing safe multi-crane lifts
Thanks to this edition’s contributors
CALL FOR CONTENT
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MISSED AN ISSUE? Current and previous issues are all available for download on our website. Visit the archives at; liftingmatters.com.au
From the Editor Q4, October - December, 2019 Welcome to the Q4 2019 edition of Lifting Matters. This quarter we decided to explore multicrane lifts (also referred to as tandem lifts). It was a fantastic learning experience for me in the compilation of this edition. In pulling together various contributions, it became apparent that multi-crane lifts are something we really struggle with as an industry! There is difficulty in interpreting the Australian Standards, as well as state regulations to meet, and of course, differences internationally. Multi-crane lifts provide an interesting intersection between safety and engineering that we often don’t fully appreciate. Thankfully, I was able to connect with some highly experienced lift engineers and safety personnel to work through this, including Kevin Ball who is the Group Safety Manager at Smithbridge Group/Universal Cranes and a representative on the Australian Standards and ISO committees, Alice Edwards from CICA and subject matter experts at Worksafe Qld. I hope you all learn as much from these people as I have!
Please get in touch with us! You can visit us on Facebook, LinkedIn or drop us an email any time. If you have an incident report, ideas about safer and more efficient ways of working, widespread issues, valuable reminders or anything else safety-related, we want to hear from you. We look forward to working together to protect our people and save lives in the crane industry. Any contributions for our next edition are due by 15 November 2019. If you prefer printed glossy copies for your crane cabs, cribs, mess hall, or reception, please send your postal address and the number of copies you require to liftingmatters@writestrategy.com.au. Lifting Matters is available to view at www.liftingmatters.com.au, or you can subscribe to receive an email copy each quarter. Stay safe and see you next edition!
Thank you DASHELLE BAILEY, EDITOR liftingmatters@writestrategy.com.au
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Contents EDITORIAL
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FEATURE ARTICLE Multi-crane lifting
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INCIDENT REPORT Caracas, Venezuela Mississippi, USA Alphen aan den Rijn, The Netherlands New Delhi, India
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IN THE NEWS LATELY Crane hits powerline Crane overturned
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SPOTLIGHT ON MULTI-CRANE LIFTS Taking collaboration to new heights
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TOPIC COMMENTARY Understanding the load distribution for multi-crane lifts
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WORKING SAFELY Multi-crane lifts in Queensland
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OPERATOR’S OPINION How technology is key to improving safety
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PEOPLE PROFILE Gordon Stone
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MENTAL HEALTH WEEK 2019 Four steps to prevent psychological injury in your workplace
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Feature Article
Multi-crane lifting KEVIN BALL Group Safety Manager, Smithbridge Group/Universal Cranes Standards Australia Committee Member Several of the most high-profile crane accidents of recent times have been those involving multiple cranes (also referred to as tandem lifts). When there are two or more cranes involved in an incident, the impact and outcome of the incident is often magnified. It figures – right? Double the equipment, double the personnel, double the consequences! The complex nature of lifts involving multiple mobile or crawler cranes makes them particularly hazardous. 6
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It’s always important to properly plan any lift, but even more so when there are several cranes involved. Multi-crane lifts are among the most technically complex lifts to plan and execute. As an industry, we generally struggle with lifts involving multiple cranes. The Australian Standards or international equivalents can be difficult to interpret. There is also often a layer of state or local guidelines to meet, which can be at odds with national standards. Guidelines differ between
Feature Article states and countries. Therefore, I must preface this article by saying it will not be possible for me to outline the specific requirements of your local region. I encourage you to do your own research in this regard, but I will attempt to provide some general things to be considered when planning and executing a multi-crane lift.
What is a multi-crane lift?
It’s always important to properly plan any lift, but even more so when there are several cranes involved
Put simply, multi-crane lifts are those which involve two or more cranes to support a load either with hooks attached directly to the load by slings, through shackles attached to pad eyes, or directly to an equaliser beam. Upending a vertical vessel using two cranes, one at the top end and a tailing crane on the bottom end is also considered a multi-crane lift. Note, we are not talking about synchronised lifts here. As outlined in AS 2550.1, clause 1.4.13, a Synchronized motion means “Two or more crane motions under the control of a single command output with bidirectional communication so that the behaviour of one motion causes identical behaviour of the others”, which means they are electrically or mechanically connected – something that overhead and gantry cranes can achieve. However, it is not practical in the mobile crane world. Therefore, we are concentrating on most of the lifts that utilise mobile cranes.
Note, the powerlines in this photo were de-energised for the lift execution.
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Feature Article
Hazards of multi-crane lifts We have come across many tragic incidents from all across the world that involved multiple cranes, a few of which are profiled in this issue of Lifting Matters. These incidents reveal critical areas of required understanding when planning a multicrane lift:
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Appropriate load planning for tandem lifts (more on that later)
•
Real-time information and communication for operators to ensure lift and travel is carried out in unison
•
Side loads/forces acting on the crane boom or unintended load distribution
•
Ground preparation and the compounding ground pressures if cranes are close to each other
•
Appropriate use of lift rigging or equaliser beams
This list is by no means exhaustive but does represent some of the key areas of consideration for tandem lifts.
Lift Planning – developing the Lift Plan Lifts involving two or more cranes are complex operations requiring considerable skill and planning. As a result, tandem lifts must be planned and carried out under a competent person’s supervision. 8
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As always, multiple lift operations must be preceded by a documented risk assessment that records known hazards and details the relevant controls. In other words, plan the works thoroughly well before the work commences. The most important thing to note in your lift plan is that tandem lifts require you to make specific calculations about the required capacity of the cranes. You must understand the load share for each crane, the total weight of everything under the boom head (including the hook, rigging, spreader beams, equalising devices etc.) and then add a percentage factor to the total lift load. The percentage depends on the number of cranes involved in the lift, depicted as follows for each crane:
a.
2 cranes – add 20% of the calculated share of the load
b.
3 Cranes – add 33% of the calculated share of the load
c.
4 or more cranes - add 50% of the calculated share of the load
The result of this calculation will provide the required capacities for each crane. In all options above, note the load may not always be even, thus load sharing must be taken into consideration. Alice Edwards from Crane Industry Council of Australia provides more detail on this, and I encourage you to take a look at her information at www.cica.com.au Some of the other key components of the Lift Plan that must be taken into consideration are:
Feature Article
1.
A site visit to understand the environment, overhead structures, ground conditions, access and site restrictions etc.
2.
The lift study must be completed by competent personnel and include the crane selection criteria
3.
Cranes should be of the same type (i.e. all telescopic mobile cranes). If not, the lift is deemed as a designed lift (see clause 6.27 of AS 2550.1)
4.
The centre of gravity requires special attention, especially for complex structures and loads, when determining crane sizes and load sharing
5.
Load sharing for rigid structures requires special attention, as the weight transfer when lifting or placing a rigid load is critical
6.
An analysis is required to understand the stiffness – strength of the load to identify the load shift effect if the cranes get out of sync
7. 8. 9.
Remember the load is everything below the boom head, so all hooks, rigging, spreader beams, load equalising devices etc. are to be included in the load calculations Cranes must travel in the same direction The communication method is critical to enable unison in movements – for example, using two-way radios, or when a clear line of sight is possible between all crane drives and the lift caller, then hand signals may suffice LIFTING MATTERS
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Feature Article
On the Job Aspects to keep in mind when on the job:
1.
2.
3.
4. 5.
6.
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Review the Lift Plan with all people involved in the lift. If there are any changes to the Lift Plan ensure these are documented and all changes are communicated to all members of the lift team. For Australian based work, person(s) involved with any rigging work, must hold a High-Risk Intermediate Rigging Licence (RI) as a minimum. Appoint a senior lift supervisor on-site to coordinate the lift who is the sole person in charge of the lift for clear accountability. The senior lift supervisor must hold a RI licence as a minimum. Make sure the person calling the lift (i.e. in radio communications with all personnel involved in the lift) holds an intermediate rigging qualification as a minimum. Stay committed to your communications plan for the lift. It is critical that this is implemented and maintained as per the Lift Plan. Consider dropping the auxiliary hook around 4m, which then acts as a great plum bob to help you keep your hoist ropes vertical, thus preventing side loading on the boom.
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Feature Article
7.
8.
Take note of passover load transfers - where the load is lifted from one end of a truck as it moves forward or backwards for the other crane to pick up the other end of the load. Take note of tailing load transfers – where a load is rotated from the vertical to horizontal, or in reverse. Ensure there is only one motion at a time and in the same direction. For example: a. If pick and carrying, lift the load, then move into position. Don’t do both and make sure all cranes are travelling in same the direction
9.
b. Special note to crawler cranes, make sure the drive sprockets are to the rear of the travel, and the cabs are facing the same way. c. Special care needs to be exercised when crabbing. If multiple cranes are crabbing, care must be exercised so that all are travelling in the same direction and do not exceed the loads detailed in the Lift Plan.
10.
Perform the lift with extreme care and at low speeds.
11.
Remember anyone can stop the lift. If something is not quite right, stop the lift and consult with the senior lift engineer.
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Feature Article
Want to know more? There are various guidelines and standards applicable to different states within Australia, nationally and internationally. We strongly recommend you research and understand the local applicable guidelines and standards. As an example, Western Australia has its own unique regulations, which are outlined in more detail by a local specialist later in this issue. Here’s a starting point for guidelines on multi-crane lifts:
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Australian Standard AS 2550.1 – Cranes, hoists and winches – Safe use, General Requirements – Section 6.28 Multiple Hoist or Crane Operation
•
Australian Standard AS 2550.5 - Cranes, hoists and winches – Safe use, Mobile cranes – Section 3 Selection
•
The Crane Association of New Zealand has published an excellent handbook called the Crane Safety manual and Section 9: Part D covers multi-crane lifts in detail.
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Incident Report
December 2013
Caracas, Venezuela Project
60t truss beam lift
Cranes
Two 100t Liebherr LTM1100-5
The Outcome
Damage to both cranes Punctured diesel storage tank resulting in road closure Minor injuries
Key Learnings
• Understanding ground conditions is critical. • Appropriate ground studies should be conducted and
recommendations made, especially as consequences are compounded in multi-crane lifts.
On 6 December 2013, two crane operators escaped with minor injuries after their five-axle all-terrain cranes collapsed while attempting a 60t truss beam lift at the site of the Tamanaco Station in Caracas, Venezuela. It is understood the two cranes performing the dangerous maneuvre were 100t Liebherr LTM 1100-5. They were positioned on opposite sides of a large access shaft, working in tandem to move a truss beam into place on top of the shaft. An outrigger on one of the cranes sank into the ground, destabilising the crane, and causing it to turn onto its side. As one end of the truss beam dipped into the shaft, it pulled the second crane over and into the shaft. Initially, the second crane was hanging on by one outrigger beam. However, it is reported to have later slipped all the way in. 14
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Incident Report
A diesel storage tank was punctured as the second crane collapsed into the shaft, resulting in a leak and closure of the adjacent road for a few hours. Thankfully, both crane operators survived their respective falls, walking away with only minor injuries given the severity of the incident.
Key learnings from this incident As can be seen from this incident, understanding ground conditions is critical. A geotechnical engineer must be engaged to conduct appropriate ground studies and make recommendations on the crane location and pad design. This is even more critical in multi-crane lifts because if ground pressures are not adequately planned for, and this results in a crane collapse, the connected crane will be pulled down by the lateral movement of the other crane, thus compounding the consequences.
While likely not the case in this incident because the cranes were located on opposite sides of the shaft, the topic of ground conditions is also a reminder that in tandem lifts when cranes are near to each other, the ground pressures for each crane will be affected by the other crane, requiring sophisticated calculations on ground conditions.
Image source: Vertikal.net https://vertikal.net/en/news/story/19048/tandem-lift-overturn-in-caracas LIFTING MATTERS
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Incident Report
June 2014
Mississippi, USA Project
Supply vessel assembly
Cranes
Two 16000 Manitowoc Cranes plus third
The Outcome
One operator permanently disabled. Four others injured.
Key Learning
• Appropriate de-rated load planning is required for tandem lifts backed up by real-time information for operators to enable both the lift and travel to be carried out in unison.
Multiple cranes were engaged to lift and place a 250-tonne bow unit for the assembly of a large supply vessel at a Mississippi shipyard. The tandem ‘lift and travel’ maneuver required two Manitowoc 16000 Crawler Cranes to lift, travel and align in unison.
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When one crane pulled ahead of the other, the second Manitowoc tipped forward. While the operator attempted to recover, the massive weight meant the crane’s load slipped, crushing the cab and throwing the operator through the windshield in the process. The operator suffered a broken
Incident Report
pelvis and crushed skull. While he survived, he suffered a traumatic brain injury. He is now blind and has severely reduced mental capacity. One of the cranes fell into a warehouse building at the VT Halter shipyard, injuring four others. The shipyard bore the most responsibility for the accident. The jury’s verdict found Manitowoc should bear 40 per cent of the responsibility, and the operator, 10 per cent. The shipyard was cited with four serious violations due to:
• • • •
the absence of clearly visible load charts; exceeding the rated load capacity; the designated person did not ensure proper positioning of spotters and did not ensure the cranes made the predetermined movements; failing to load test the lower load cell sensor on the main hoist after it was repaired.
Image source: Crane Institute of America https://craneinstitute.com/news/three-cranes-lifting-a-load-what-can-be-more-complicated LIFTING MATTERS
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Incident Report
Key learnings from this incident With multiple cranes working in tandem, both the movement of the load and crane travel needs to be perfectly choreographed. Travelling means that dynamic forces come into play when synchronisation is off. Being off by the slightest amount can result in a catastrophic imbalance. This incident shows how wrong a tandem lift can go when load planning failures are compounded by inadequate sensor and positioning information being available to the operator.  18
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Incident Report
July 2009
New Delhi, India Project
Metro Rail Project
Cranes
2 x 250 tonne Grove; 350 tonne Krupp; 400 tonner (unspecified) Three of the four cranes collapsed. Five people received minor injuries.
The Outcome Key Learning
This lift was ‘planned’ and executed in less than a day. The level of planning required was completely underestimated or ignored.
Three cranes collapsed injuring five people less than a day after a 6-person fatality was recorded at the same site. The Metro Rail – part of New Delhi’s preparations for hosting the 2010 Commonwealth Games – was a significant project with disturbing safety statistics. The day before the attempted four-crane lift, a subway beam under construction collapsed killing six people and injuring 15 others. The four-crane lift was an attempted recovery of the collapsed beam which got underway the next morning. It is understood once the full weight of the beam was taken by the four cranes, the boom of the first crane (a 250 tonner) snapped under the weight passing a greater load onto the 350 tonne Krupp causing its boom to tear off entirely. The next crane (a 250 tonne Grove TM2500) tipped and its counterweight sections plummeted to the ground. The fourth crane (400 tonner)
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Incident Report
remained upright as that end of the bridge beam had only been lifted marginally when the collapse occurred at the other end.
Key learnings from this incident A four-crane lift of an unsteadily placed beam in congested conditions requires a tremendous planning effort. While there is limited data available, less than 24 hours of planning took place for this complex lift. The immediate failure of the 250 tonne Grove and complete shearing off of the 350 tonner would suggest planning was wholly inadequate or non-existent. It was remarkable no-one was seriously injured. 20
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Incident Report
The first 250t Grove tipped on its end. The boom of the 350t was torn in two.
Image source: ABC News https://www.abc.net.au/news/2009-07-14/heavy-cranes-collapse-during-clearing-operations/1351922 LIFTING MATTERS
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Incident Report
August 2015
Alphen aan den Rijn, The Netherlands Project
Koningin Juliana Bridge
Cranes
Terex AC700 and Liebherr LTM 1400-1
The Outcome
Major damage to shops and houses. No injuries.
Key Learning
• Dual lifting over water has added complexity. • With multiple contracting parties, planning needs to be integrated, and responsibilities made clear.
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Incident Report
Miraculously no one was injured when a lift involving two barge-mounted cranes failed. Both cranes and the section of the bridge they were attempting to lift crashed into the neighbouring properties which lined the banks of the Oude Rijn (Old Rhine) river. Several homes and shops were destroyed, but no one was injured in this incident. The aim was to lift and then maneuver a new section of the Koningin Juliana Bridge into place. Two mobile cranes – a 400-tonne and 700-tonne – were mounted on separate barges and set to carry out a dual-lift of the bridge section from a third barge. The barge carrying the smaller crane tipped to the extent the crane’s mast failed, causing the 400-tonner to topple over. This resulted in a domino effect as it pulled the lifted bridge section with it, which in turn caused the large crane to also topple. The Dutch Safety Board’s report revealed the lift engineering was entirely flawed.
This incident was included in the March 2019 edition of Lifting Matters where we highlighted the need for extensive planning and a clear chain of responsibility when working over water. It also highlights the additional forces and risks to be managed in tandem lift scenarios.
The official report found there was inadequate stability in the lift design. The lift plan did not allow for variables such as wind, or the crane movements. On top of this, the cranes were loaded to 100% of their rated capacity, and there was no ballasting plan for the barges to enable timely adjustments to be made. Multiple subcontractors were involved in the lift, and each made assumptions about what each other were planning. Despite this work being carried out in an urban area, no consideration was given to the safety of people in the vicinity.
No matter how precisely the lift was executed, it was destined to fail. Both crane operators involved had limited tandem lift experience, and both underestimated the complexity and risks involved. Information and photo source: Dutch Safety Board, Lifting Accident Summary Report LIFTING MATTERS
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In the News Lately
Our December 2018 edition of Lifting Matters looked at overhead power lines and dispelled common myths power lines and flow of electricity. Go to www.liftingmatters.com.au/ archives for more information.
July 2019
Crane Hits Powerlines Little Mulgrave, Far North Queensland, Australia In July 2019, a 49-year-old man sadly lost his life by electrocution, and two others were transported to the hospital when a crane boom hit a powerline in Far North Queensland. The workers had been laying tracks for a sugarcane train line at Little Mulgrave, 37km south of Cairns. It is understood the crane driver was maneuvring a length of track as the dogman walked beside and steadied the load. The boom of the crane came into contact with powerlines, electrocuting the dogman.
second man was hospitalised with severe burns, and a third man was treated for emotional distress. The 54-year-old crane driver is now facing court in September 2019 after police alleged he did not have appropriate licences while operating the crane at the time of the accident. An ongoing investigation into the incident was being conducted by Queensland Workplace Health and Safety at the time of publication.
A nearby resident heard screams and rushed to the site of the accident, performing CPR until emergency services arrived. One man suffered fatal burns, a Image source: The Australian https://www.theaustralian.com.au/nation/one-dead-as-crane-hits-powerlines/news-story/46b8b95151fb36884bdac8d347ce19ff - Pictures above: Anna Rogers 24
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In the News Lately
July 2019
Crane Overturned Mareeba, Far North Queensland, Australia In Far North Queensland, July 2019, a second crane incident in as many days saw two men horrifically injured in a mobile crane rollover. A 38-year-old man and a 52-year-old man were driving a Terex Franna crane along Mareeba Dimbulah Road (~40 kilometres south-west of Cairns) when they lost control trying to overtake a slow-moving tractor around 9.30am. The crane came to a rest after flipping onto its cab roof. According to police, the two men were still inside the crane cabin when emergency services arrived. The road was closed in both directions to allow emergency service and helicopter access.
One man was flown by rescue helicopter to Cairns Base Hospital suffering fractures to his skull and neck, two broken collarbones, 12 broken ribs, punctured lungs and a compound fracture to one of his legs. The other man was taken to Mareeba Hospital with severe head and neck injuries. Both men were placed into an induced coma but are now on the long road to recovery surrounded by family. Investigations were underway to determine the cause of the crash. Our September 2014 edition of Lifting Matters covered the stability of Franna cranes. Go to www.liftingmatters.com. au/archives for more information.
Image source: ABC News https://www.abc.net.au/news/2019-07-29/two-men-were-critically-injured-when-this-crane-rolledover-at/11361218 - Picture: QPS LIFTING MATTERS
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Spotlight on multi-crane lifts
A 350t Liebherr LTM1350 & 130t Grove GMK5130 were used to carefully lift a redundant vessel onto transport.
Multi-crane lifts Taking collaboration to new heights
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Spotlight on multi-crane lifts
A Demag AC350 and Grove GMK7450 worked together to install bridge beams for The Northern Corridor improvements (NCI) project in Auckland.
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Spotlight on multi-crane lifts
The St Pauls Cricket Pavilion in Auckland was lifted by a trio of Grove cranes (GMK5130, GMK4100, and GMK3055).
These air conditioning components were lifted by a sweet pair of 5t Mini Crawler Cranes (Maeda CC505).
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Spotlight on multi-crane lifts
A Demag AC300 and crawler crane synchronised a tandem lift of a vessel in New Zealand.
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Topic Commentary
Understanding the load distribution for multi-crane lifts Article contributed by Alice Edwards, Technical Project Engineer – The Crane Industry Council of Australia (CICA) Multiple crane (means a lift operation that requires two or more cranes) arrangements/methods are sometimes used on lifting jobs when physical dimensions, characteristics, mass, required movement of the load, environmental restrictions or other factors prevent the 30
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lifting operation from being performed by a single crane or single hoist. Multiple crane lifts can range from rotating a column using a lift crane at the top and a tailing crane at the bottom, to lifting a pre-assembled platform with eight cranes.
Topic Commentary In general, these considerations may determine when you would choose a multiple crane lift (this is not a blanket fixed set of rules):
• •
If the load would be out of sight of the crane operator if it were a single crane or single crane dual hook operation. If there is a large distance between lift point locations relative to the boom length, which would impact on retaining pins, localised stress distribution and other elements of the crane.
Lifting with multiple cranes is always more complex than lifting with just one crane, so appropriate planning, engineering and operational control measures need to be in place to manage the risks associated with multiple crane lifts. One critical control measure is to calculate the distribution of the load among the cranes and how the load distribution will change for the entire lifting process. Configuration of the load to be lifted (i.e. size, centre of gravity (CoG), lift point position) can be used in the moment equation to calculate the load distribution (see a simple example of a load share calculation on this page). The closer a crane is to the centre of gravity, the more load the crane will receive. This example uses two cranes, the same principle can be used for three or more crane lifts, but the calculation will be much more complex as the cranes are not evenly spaced either side of the centre of gravity.
X = 2m
Y = 1m 4m
From the above example, we can see that knowing the centre of gravity is very important, and through the planning stages, attention needs to be applied for non-uniform densities or weight distributions. When lifting a load from the supports or placing the load onto the supports, because the cranes may not be able to lift the load in perfect tandem, the load share between the load and the support can change dramatically. In the load share calculation example we mentioned above, if Crane B put the load down on support C, and Crane A is still holding the load, then load share for Crane A changes from 0.67t to 1t, which means 33% load increase for Crane A, this
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Topic Commentary needs to be factored in when selecting the correct size crane for Crane A.
X = 2m
Z = 2m 4m
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During the lift process, if the distance of the CoG to the lifting point changes (i.e. rotation) the load share between the cranes will change (see example graph below for load share change between the main crane and the tailing crane). This may happen gradually or dramatically depending on the geometry of the load and the lifting speed. It is important to calculate the load share between the cranes for the entire lifting process to size the cranes correctly.
Topic Commentary For multiple crane lifts, the movement of the load between the cranes will create extra loadings on the cranes. These loadings include horizontal forces acting on the boom and additional vertical load. These can occur from misalignment in cranes to load, load shifting, minor errors in centre of gravity location and general crane motions. When performing a multiple crane lift, a documented lift plan and procedure should be prepared by a competent person (i.e. an engineer) and followed. Lifting operations using two or more cranes at the same time must use cranes of the same type. If different types of cranes are used together (i.e. mobile cranes and tower cranes are used together for a multiple crane lift), then the lift would require a designed lift assessment. Other than a designed lift, the following minimum capacity requirements for each crane shall apply as a safety margin:
If the calculated maximum load share for the crane to be used is 10t, then in a two-crane lift operation, the rated capacity of the selected crane shall be at least 12t for the planned crane configuration. A multiple crane lift is a complicated operation, so more precautions are necessary when planning the lift. Detailed control measures and using experienced lifting personnel (the person in control of the lift must hold at least an intermediate rigging high-risk work licence) are key success factors. However, understanding the load distribution is the first step to a safe lift.
For two cranes
20% greater than the calculated share of the load.
For three cranes
33% greater than the calculated share of the load.
For four or more cranes 50% greater than the calculated share of the load.
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Working Safely
Multi-crane lifts in Queensland Article contributed by Worksafe Qld Workplace Health and Safety Queensland has investigated two serious incidents involving dual crane lifts over the last two years.
In the first incident, two cranes on outriggers were lifting a 50 tonne Super T bridge beam, and the driver was unable to see where the load was being placed.
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The beam was not symmetrical, with a precast barrier attached to one side. When the load was released from the crane hooks, the beam fell to the outside, knocking out both the temporary support brackets and a wing wall on the bridge and injuring two workers. The incident could have been avoided if the beam had been tied to other Super T’s already installed, before taking the load off the hoist ropes. In the second incident, two pick-and-carry cranes were moving a load around a corner
Working Safely when one of the cranes overturned. The load indicator wasn’t working on one of the cranes, and the load was much heavier than previously thought. Multiple cranes are simultaneously used to lift a load when it is too heavy for a single crane, or its shape requires multiple cranes to make sure it’s stable during lifting or rotate it during the lift. Using multiple cranes simultaneously to lift a load increases the risk of the lift because:
•
individual crane loads can increase during the lift as the load’s centre of gravity shifts or the hoist ropes move away from vertical
•
each crane’s actions can affect the stability of other crane/s involved in the lift if operations are not synchronised. Maximum rated capacity limiters not designed for this operation may not prevent the crane from operating beyond its limits
•
hoist rope angles can cause a push/ pull effect.
It’s important to properly plan crane lifts and avoid using multiple cranes if it is possible to do so safely. However, where multiple cranes must be used, the following precautions should be followed:
•
Conduct a lift study during the planning phase (including load share and how it will be managed during the lift).
•
Identify structures, plant items and powerlines which may restrict crane movement or could be contacted during the lift.
•
Seek advice from the crane manufacturer or an engineer on wind sail effects – particularly for loads with a large surface area.
•
Make sure cranes of equal/similar capacity and characteristics are selected for the lift and that each crane is capable of safely lifting its share of the load at the maximum radius to be lifted at, including an additional factor of safety for multiple crane lifts (outlined in section 13.3.2 of the Mobile Crane Code of Practice 2006).
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Check the combined mass of rigging gear, lifting hooks, slings and fly jibs (if used) is deducted from the maximum rated capacity of the crane at the required operating radius.
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Analyse uneven mass distribution in the load to be lifted.
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Ensure ground conditions are suitable for all cranes in operation.
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Working Safely
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Use experienced operators for a multi-crane lift with the appropriate high-risk work licences - remember an intermediate or advanced rigger must be in control of the lift.
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Use equaliser lifting beams and associated equalising sheaves where needed.
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Ensure load indicators are fitted to all cranes involved, and they are working accurately.
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Ensure clear methods of communication between all parties involved are in place.
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Remove non-essential personnel from the work area.
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Make sure both cranes are aligned in the same direction when using non-slewing type cranes in the pick-and-carry mode.
In summary, the use of multiple cranes to simultaneously lift a load is a specialised operation that should only be conducted if the use of a single crane is not possible. In any type of crane lifting operation, the failure to follow a safe system of work can have catastrophic results.
For more information on crane safety, visit worksafe.qld.gov.au. Workplace Health and Safety Queensland
Get involved this
Safe Work Month 1-31 October
Register for a Safe Work Month event near you or host your own safety themed event. worksafe.qld.gov.au/safe-work-month
@SafeWorkQLD
Dow your nload even free t kit.
@SafeWorkQueensland
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Incident Report
CALL FOR CONTENT Contribute to Lifting Matters’ vision of a safer industry by submitting your ideas and articles to: liftingmatters@writestrategy.com.au
Contributor (content and images): Vertikal.net LIFTING MATTERS
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Operator’s Opinion
How technology is key to improving safety Have you personally been involved in any multi-crane lifts? Yes, I have been involved in all stages from planning through to performing the lift. I have learnt that inexperience can result in overcomplicating and overthinking the lift – although there are factors you must consider outside of general lifting – sometimes less is more and it doesn’t need to be as complex or difficult as people think. What is the most common action or behaviour you witness in the field when operators don’t plan for multicrane lifts appropriately, and how do you think we can fix it?
Ryan Pardoe Auckland Cranes
Ryan Pardoe has been in the crane industry for 13 years, working across multiple countries including Australia, New Zealand, and Papua New Guinea. Ryan is currently based in New Zealand, having recently started work with Auckland Cranes as a Crane Operator.
The most common behaviour I see is communication consisting of head nodding and shouting out the door between operators. It would be great for people to take the time to understand what’s involved, plan properly, and communicate accordingly. I have a lot of faith in the likes of CICA and the Crane Association of New Zealand, and I believe they can make a substantial impact on the industry through promoting the right message for employers and workers to upskill and get the required training they need.
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Operator’s Opinion
Have you any thoughts or ideas on innovation or process that may help to prevent or alert workers when multi-crane lifts are potentially unsafe? I believe technology is key to improving safety. Simplifying processes and making tools more easily accessible will help people make better, safer, and more informed decisions. Seeing a need to help educate people in the industry is why I developed a free app called Rigsafe. It’s designed to help riggers select the right rigging for the task and make the right decision from the start. What do you feel is the most important safety issue affecting your particular role in the industry today? We have a bit of a laid-back culture of “she’ll be right” or “I’ve done it like this for 30 years mate!” People need to understand why what they’re doing is right – not just because it’s the way they’ve been shown or told, but because they recognise the requirements of the task and can make calculated decisions for the job. It’s so important that this understanding is passed on to future generations so that they are equipped with the knowledge to achieve the best possible outcomes. This will not only help to reduce incidents but will improve the overall safety culture of the crane industry.
Rigsafe helps you select the right lifting gear for the task. Head to Google Play for your free download (only available on Android)”
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People Profile
Gordon Stone
e Gordon Ston
Director, on Ltd & Constructi Smith Crane
Gordon Stone retired from full-time work in 2013 after a 45-year career at Titan Cranes in New Zealand. It wasn’t long before he was snapped up in 2017 as a Non-Executive Director at Smith Crane and Construction Ltd. Gordon is a mainstay of the New Zealand crane industry, having served on the Crane Association for over a decade. We were privileged to catch up with Gordon to learn more about his journey and impact on health and safety in the crane industry.
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Wow, congratulations on 50 years in the New Zealand crane industry. Tell us about your journey so far. I started at the Ministry of Works at Gracefield, where I obtained my advanced trade certificate in fitting, turning, and machining. There, I connected with Max Whiley, founder of Titan Cranes, and his workshop man Frank Wicksteed, who both came to the auctions to purchase used machinery. After a bit of pay negotiation, I started working for Titan Cranes in 1970 as a fitter during my holidays. Eventually, I took over crane maintenance, before being dispatched to Christchurch in 1979 as Titan Cranes expanded. I went on to become Christchurch manager in 1990, and then South Island manager once a branch was opened in Dunedin. In 2008, I was appointed General Manager, and then Chief Executive in 2009. Meanwhile, I was also elected to the Crane Association national executive in 1994 and served as President from 1999-2001 then spent several years as past president. In 2013 I retired from full-time work at Titan Cranes. Around this time, I was asked by Tim Smith to join Smith Cranes on an advisory board. Since I now had the time and was still very interested in the crane industry, I accepted and became Director of Smith Cranes and Construction. It has been great to see the growth in the company to date.
People Profile How have you been involved in shaping health and safety in the New Zealand crane industry, and what did you learn in these experiences? I helped form the Power Crane Association ITO, where we wrote the first unit standards and eventually got them accepted by the Qualifications Authority. I was also involved in the rewrite of the Crane Association Safety Manual. In this process, I learned that training and safety culture simply go hand in hand. Building an effective safety culture is all about communication, finding solutions, and continually reviewing procedures. It’s important that we put resources into training and preserve the mindset of continual learning. Another little tip – get to know the people in the regulatory bodies and get alongside them, because they don’t understand your business sometimes and you’ve got to run alongside them. If you can build relationships, it’s much easier to get things done. What do you think is the most important issue in crane safety today? I believe that the most important issue facing the crane industry today is ensuring continuous improvement in the next generation of workers. It’s so important to get young people involved and interested in making a career out of cranes. Whether it is in operations, maintenance, management, or other areas, they will be rewarded by working in such an interesting and diverse industry.
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Mental Health Week 2019
Four steps to prevent psychological injury in your workplace Article contributed by Safe Work Australia Just like work-related physical injuries and illnesses, psychological injuries or illnesses take a significant toll on worker health, safety and productivity. And just like physical injuries, the impact extends from the individual to their families and colleagues. Psychological injuries are increasing in workplaces and are one of the most expensive work-related injuries in Australia. Safe Work Australia data states workers’ compensation claims for psychological injuries typically result in more than three times as long off work and cost more than twice as much as physical injuries1. Work pressure, harassment or bullying, and exposure to workplace or occupational violence are the leading causes of workrelated stress and can happen to anyone in any workplace. The good news is psychological injuries in the workplace are preventable. Everyone has duties under work health and safety (WHS) laws. Under WHS laws, psychological hazards and risks are treated the same as physical hazards and risks. Preventing psychological injuries, starts with recognising that businesses can do something to prevent them by taking action
and intervening early to identify hazards and eliminate and control the risks. When identifying hazards, look for anything that could cause harm. Psychological hazards are anything that increases the risk of work-related stress. Stress by itself is not an injury but if prolonged or severe, it can cause psychological and physical injury. Psychological hazards include:
• • • • • • • • •
high or low job demand poor support poor workplace relationships low role clarity poor organisational change management poor organisational justice poor environmental conditions remote or isolated work, and violent or traumatic events.
Sourced from Safe Work Australia’s National Data Set for Compensation-based Statistics. These are based on the figures for all serious claims between 2012-13 and 2016-17p. Serious claims are defined as accepted compensation claims which resulted in one or more working weeks lost (excluding fatalities and journey claims). The data for 2016-17 is preliminary and subject to change when new data is available. 1
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To manage psychological hazards, follow the four-step process: 1. Identify psychological hazards To identify hazards, talk and listen to workers, inspect the workplace, notice how people interact, review records (e.g. reporting systems, staff turnover and absentee reports) or use tools such as staff surveys.
2. Assess psychological risks To assess risk, consider what could happen if someone is exposed to that hazard, the degree of harm that may result and the likelihood of that outcome. If the risks associated with a particular hazard are well known – you can skip this step.
3. Control psychological risks The hierarchy of controls ranks ways of controlling risks from the most reliable to the least. This hierarchy helps to find the most effective control measure (or combination of control measures) for risks, including psychological risks.
4. Review control measures Control measures need regular review. Maintaining and monitoring them regularly can ensure they are working. Reviews can include the same methods used to initially identify the hazards.
Consultation Consulting workers is essential. The people doing the work are the experts in the work they do and the impact it has. Once a conversation is started, workers can identify parts of their work which cause stress and may already have ideas on how to fix them.
Safe Work Australia’s Guide Work-related psychological health and safety: A systematic approach to meeting your duties steps you through how to apply the risk management process to psychological risks and what to do at each step. Your WHS regulator can provide advice on this process and tools to assist you. Safe Work Australia is raising awareness of workplace mental health during National Safe Work Month in October. This includes recognising Mental Health Week 2019, which falls in the second week of October. To find out what is happening in your state, contact your WHS regulator or visit safeworkaustralia.gov.au/nationalsafeworkmonth. LIFTING MATTERS
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Any questions? Want to support? Contact us! liftingmatters@writestrategy.com.au www.liftingmatters.com.au
Content deadline for next issue: 15 November 2019 Next issue available: December 2019
Disclaimer – This newsletter is not an exhaustive list of all safety matters that need to be considered. Whilst care is taken in the preparation of this material, Lifting Matters does not guarantee the accuracy and completeness of this information and how it applies to your situation. Lifting Matters will not be responsible for any loss, damage or costs incurred as a result of errors or omissions in relation to the material in our publication or for any possible actions ensuing from information contained in our publication. Any views or opinions represented in this publication are personal and belong solely to the author and do not represent those of people, institutions or organisations that the publisher may or may not be associated with in a professional or personal capacity unless explicitly stated.